Bobcat al275 wheel loader service repair manual sn adbh11001 & above

Printed in Europe
AL275
S/N ADBH 11001
& above
Service Manual
4950152 (10-09) (A) © Bobcat Europe, 2008
EN
AL350
S/N ADBJ 11001
& above
AL440
S/N ADBK 11001
& above
1 of 196

4950152-EN (08-08) ALPHA-1 Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
ALPHABETICAL INDEX
Air filter, air intake...............................................10-90-15
After shutdown ...................................................10-100-1
Axles ..................................................................10-90-23
Battery charge......................................................60-20-1
Brakes ................................................................10-90-19
Breather .............................................................10-90-22
Cable colours .....................................................30-10-16
Cab ventilation dust filter....................................10-90-26
Care and cleaning................................................80-20-1
Cable connections..............................................30-10-18
Checking, maintenance and inspection plans....80-110-1
During shutdown ................................................10-100-1
Drift values ...........................................................40-10-2
Engine oil ...............................................60-10-1, 10-90-5
Engine oil cooler (AL275).....................................10-90-7
Electrical equipment...........................................10-90-25
Fan belt ..............................................................10-90-18
Fuel ....................................................................20-140-1
Fuel system........................................................10-90-10
Flow diagram......................................................30-10-18
Fuse box - Assignment diagram AL275 ...............30-10-1
Fuse box - Assignment diagram AL350 ...............30-10-6
Fuse box - Assignment diagram AL440 .............30-10-11
General Notes ....................................................20-130-1
Hydraulic oil.........................................80-170-1,10-90-20
Hydraulic oil cooler.............................................10-90-20
Hydraulic diagram AL275.....................................50-10-1
Hydraulic diagram AL350.....................................50-20-1
Intervals..............................................................60-150-1
Inspection parts and aids .....................................60-80-1
Injection valves...................................................10-90-24
Joystick...............................................................30-10-19
Overview of lubricating points ..............................30-20-1
Preservation (temporary shutdown)...................10-100-1
Regular oil analyses.....................................................10-120-1
Setting instructions travel hydraulics ....................80-30-3
SPECIFICATIONS AL275..................................................60-01
SPECIFICATIONS AL350 ....................................... 60-02
SPECIFICATIONS AL440 ....................................... 60-03
Toothed belt for engine.......................................10-90-24
Troubleshooting..................................................10-110-1
Travel drive (coNT’D)............................................20-10-2
Test Ports .............................................................40-10-1
Technical specifications AL275 ............................40-20-1
Warranty...............................................................50-50-1
Wheels ...............................................................10-90-24
Wind shield washer system................................10-90-26
Wheel loader Software V0.40...............................50-30-1
3 of 196

4950152-EN (09-08) I Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
CONTENTS
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
SPECIFICATIONS AL275. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40
SAFETY AND
SYSTEM
ELECTRICAL
MAINTENANCE
SPECIFICATION
APPENDIX
HYDRAULIC
SYSTEM
SPECIFICATIONS
TECHNICAL DATA
5 of 196

4950152-EN (09-08) II Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
FOREWORD
SAFETY INSTRUCTIONS
Introductory remarks
Please read the operating instructions carefully before
putting an earth-moving machine into operation and
strictly follow the remarks for a safe operation.
National safety regulations - e.g. the Accident Prevention
Regulations, „Earth-Moving Machinery“ (VBG 40) and
„Vehicles“ (VBG 12), in the Federal Republic of Germany -
must also be complied with.
In addition to the operating instructions, legal regulations
governing road traffic and road safety measures must also
be observed. Such requirements could also apply in
respect of handling hazardous goods or the wearing of
personal safety equipment, for example.
Furthermore, safety laws governing work in particular
locations (tunnels, adits, quarries, pontoons,
contaminated areas, etc.) must likewise be observed.
Correct use
The earth-moving machine with normal shovel equipment
is only to be used for work which is suitable for the
machine's functions and its attachment.
Such work includes the digging, loading, displacing and
dumping out the earth, stones or other materials and the
loading of these materials and the loading of these
materials onto lorries, conveyor belts or other means of
transportation. The transport of the loading material,
however, is mainly carried out by moving the earth-moving
machine.
If special attachments, such as Unishovel, side dump
shovel, sweeper, forklift attachment etc. are mounted,
special jobs can be done with the attachment.
Another or additional application, e.g. for transportation of
passengers or using the lifting device as working platform
etc. is not considered as correct use. The supplier is not
liable for subsequent damage. The end-user himself
bears the full risk.
It is part of the correct use to follow the operating and
maintenance instructions and to carry out the
maintenance as well as to follow the maintenance
intervals.
General safety notes
It is important to refrain from any working methods which
impair safety.
The earth-moving machine may only be used when it is in
a safe, operational condition.
The manufacturer's operating instructions must be
complied with for operation, maintenance, repair,
assembly and transportation.
The plant operator must provide additional special safety
instructions, wherever necessary, for specific local
conditions.
The operating instructions and any information pertaining
to the safety must be carefully kept in the driver's cab.
The operating instructions and safety notes must be
complete and fully readable.
Safety devices on earth-moving machines must not be
deactivated or removed.
Protective work clothing must be worn during operation.
Rings, scarves and unbuttoned jackets are to be avoided.
Protective goggles, protective boots, helmets, gloves,
reflecting jackets, earmuffs, etc. may be required.
Before commencing work, information must be obtained
on first aid and possible means of rescue (ambulance, fire
brigade, helicopters).
A check must be carried out to ensure that the first aid box
is at hand and that its contents comply with regulations.
Personnel must be aware of the location and method of
operation of the fire extinguishers on the earth-moving
machine as well as on-site fire-warning and fire-fighting
equipment.
Loose parts such as tools or other accessories must be
secured to the earth-moving machine.
Open doors, windows, covers, flaps, etc. must be secured
so that they cannot slam shut.
Operation
Earth-moving machines may only be independently
operated and serviced by people who
• Are physically and mentally fit
• Have been instructed in the operation or maintenance
of he earth-moving machine and have demonstrated
this ability to the plant operator
• Can be expected to perform their allocated duties
reliably
6 of 196

4950152-EN (09-08) III Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
SAFETY INSTRUCTIONS (CONT’D)
Operation (Cont’d)
All these people must be of the legal minimum age.
They must be designated by the plant operator to operate
or service the earth-moving machine.
Operating equipment (controls) may only be activated
from the driver's seat.
The earth-moving machine may only be ascended and
entered using the entrances and surfaces intended for this
purpose.
The operator has to ensure that the cab, steps and other
walked-on surfaces of the earth-moving machine are free
of dirt, grease, oil, ice and snow.
Danger zone
• No one may enter the danger zone of earth-moving
machines.
• The danger zone encompasses the area around the
earth-moving machine in which people may be injured
by movements of the earth-moving machine in which
people may be injured by movements of the earth-
moving machine during operation, its working
equipments and attachments, or by swinging out or
falling loads, or by falling working equipment.
• The machine operator may only work with the earth-
moving machine when the danger zone is free of
personnel.
• The machine operator must give a warning signal to
persons who may be in danger.
• The machine operator has to stop work with the earth-
moving machine if anyone remains in the danger zone
despite the warning.
• To ensure no danger of crushing, a sufficient safety
distance (min. 500 mm) must be kept from solid
objects, e.g. buildings, excavation slopes, scaffolding,
other machines, etc.
If the above safety distance cannot be maintained, the
area between solid objects and the working zone of the
earth-moving machine must be blocked off.
• If conditions are such that the machine operator's view
of the driving and working zone is restricted, he must
be guided or the driving and working zone must be
marked by a solid barricade.
The windows must be clean and free of ice.
Driving tracks must be designed so as to ensure smooth,
safe operation, i.e. they must be sufficiently wide, on
ground which has sufficient carrying capacity and as few
slopes as possible.
Downhill tracks must be set out in such a way that loading
machines can be braked safely.
Transport of passengers
Passengers must not be transported on the machine.
Stability
Earth-moving machines must be used, driven and
operated in such a manner that their stability against
overturning is ensured at all times.
The machine operator must drive at speeds which are
suitable for local conditions.
The permitted payload of the earth-moving machine must
not be exceeded.
Earth-moving machines must remain at a sufficient
distance from the edges of quarries, pits, mounds and
slopes to ensure there is no risk of falling.
Earth-moving machines must be secured so that they
cannot roll or slip when in the vicinity of excavations,
shafts ditches, pits and slopes.
Travel operation
Before putting the earth-moving machine into operation,
the driver's seat, mirrors and controls must be so adjusted
as to ensure safe working.
The carrying capacity of bridges, cellar roofs, vaults, etc.
must be verified before the earth-moving machine can
drive over them.
The internal dimensions of constructions must be noted
before entering underground passages, tunnels, etc.
On steep drops and uphill gradients, the load must be
carried on the uphill side, if possible, in order to increase
stability.
Before driving downhill, the appropriate gear for the
terrain must be selected and the gear lever must not be
moved during downhill travel (normal or crawler gear).
Earth-moving machines may only be driven on the open
road when both the machine and the driver have the
appropriate license as required by the country in question.
Outside areas covered by general traffic regulations, e.g.
on construction sites, traffic regulations should be applied
in the proper manner. This should also apply with regard
to drivers' licenses.
7 of 196

4950152-EN (09-08) IV Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
Operation
The operator has to check the correct fastening of the
attachments and / or lock of the quick exchange device
daily before start of operation and after every attachment
change. Move the attachment carefully at low height.
Please ensure that nobody is in the danger zone during
these checks.
The machine operator may only swing the working
equipment over occupied drivers' seats, operator
consoles and workplaces of other machines if these are
protected by overhead guards (FOPS).
If a cab does not have the required protection, the driver
of this vehicle must leave the driver's seat when the
working equipment has to be slewed overhead.
The vehicles must be loaded in such a manner as to
ensure that there is no overloading and no material can
be loaded from the lowest possible height.
At dumping points, earth-moving machines may only be
operated when suitable measures have been taken to
prevent rolling or falling.
Guides
Guides must be easily recognizable, e.g. by means of
reflective clothing. They must remain within the machine
operator's field of sight.
While guiding the machine, guides must not be given
other jobs which may distract them from their task.
Danger of falling objects
Earth-moving machines may only be used where there is
a danger of falling objects if the driver's seat and operator
consoles have an overhead guard (FOPS). A front guard
must be employed if there is a risk of materials breaking
into the cab.
In front of walls e.g. of stacked materials, earth-moving
machines must be positioned and operated in such a way
that the driver's seat and entry to the driver's seat are not
situated on the side facing the wall.
Demolition work may only be performed with earth-
moving machines where there is no danger to personnel.
Working in the vicinity of underground power lines
Before commencing excavating work using earth-moving
machines, it must be determined whether any
underground power lines are present in the intended
working zone which may present a danger to personnel.
If underground power lines are present, their exact
position and course must be determined in consultation
with the proprietor or operator of the lines, and the
necessary safety precautions decided and implemented.
The course of power lines in the work area must be clearly
marked, under supervision, before commencing any
excavation work. If the position of lines cannot be
determined, search ditches must be dug - manually, if
needed.
If underground power lines are encountered unexpectedly
or they or their protective covers are damaged, the
machine operator must discontinue work immediately and
notify the supervisor.
Working in the vicinity of overhead power lines
When the earth-moving machine is being used in the
vicinity of overhead power lines and trolley wires, a safety
distance which varies depending upon the nominal
voltage of the overhead line must be maintained between
the lines and the earth-moving machine and its working
equipment, in order to prevent current overspill. This also
applies to the distance between these lines and attached
implements or loads.
The safety distances specified below must be complied
with:
In the observation of safety distances, all working
movements of the earth-moving machine, e.g. positions of
the boom, swinging ropes and the dimensions of attached
loads must be taken into consideration. Uneven ground
which would cause the earth moving machine to be
inclined and thus nearer to overhead lines must also be
taken into account.
During work in windy conditions, both overhead lines and
working equipment may swing out, thus reducing the
safety distance.
If it is impossible to maintain sufficient distance from
overhead power lines and trolley wires, the plant operator
must consult with the proprietor or operator of the
overhead lines to find other safety precautions to prevent
current overspill. Such measures could be, e.g.
• Switching off the current
• Re-routing the overhead line
• Cabling, or
• Limiting the work zone of earth-moving machines
NOMINAL VOLTAGE
SAFETY DISTANCE IN
METERS
1000 V 1,0 m
over 1kV - 110kV 3,0 m
over 110kV - 220kV 4,0 m
over 220kV - 380kV 5,0 m
Nom. Voltage unknown 5,0 m
8 of 196

4950152-EN (09-08) V Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
Operation in closed rooms
If earth-moving machines are used in closed rooms, these
areas must be sufficiently ventilated and special
regulations observed.
Work stoppages
Before rest periods and at the end of the working day, the
driver of the earth-moving machine must park the
machine on ground with sufficient load capabilities and is
as even as possible, and must secure it against
movement.
Before rest periods and at the end of the working day, the
driver must lower the working equipment onto the ground
or secure it so that it cannot move about.
The driver must not leave the earth-moving machine if the
working equipment has not been lowered to the ground or
secured.
Earth-moving machines may only be parked in places
where they do not present an obstacle, e.g. on the
construction site or to plant traffic. Warning devices, e.g.
triangles, warning cordons, flashing or hazard lights are to
be used if necessary.
Before leaving the control console, the driver must bring
all working equipment into home position and apply the
brakes.
If the driver is leaving the earth-moving machine
unattended, he must first turn off the drive motors and
ensure that they cannot be started up by unauthorized
persons (remove ignition key for example).
Crane operations
Crane operations are the hoisting, transporting and
lowering of loads with the aid of a fixing device (rope,
chain, etc.), whereby the assistance of personnel is
required to attach and release the load.
Such work covers, for example, the lifting and lowering of
pipes, heavy machine parts or containers with earth
moving machines.
Earth-moving machines may only be used for crane
operations if the prescribed safety devices are present
and in full working order. For earth-moving machines,
these are:
• Safe fastening points for lifting device
• Table of carrying capacity
• Overload warning device*
• Hose rupture safety valve for boom cylinder*
* only in case of an admissible carrying capacity of more
than 1000 kg
Loads must be attached in such a way that they cannot
slip or fall out.
Personnel guiding the machine and attaching loads must
always remain in the machine operator's field of sight.
The machine operator must carry loads as close to the
ground as possible and prevent them from swinging.
Earth-moving machines may only travel with an attached
load if the path of travel is fairly level.
When earth-moving machines are used for crane
operations, personnel attaching loads may only approach
the boom from the side and with the machine operator's
permission. The machine operator may only give his
permission if the earth-moving machine is standing still
and the working equipment is not in motion.
Do not use fixing devices (ropes, chains) which are
damaged or of inadequate dimensions. Protective gloves
must always be worn when working with fixing devices.
Assembly, maintenance, repair
Earth-moving machines may only be assembled,
converted or disassembled under the guidance of a
suitable person designated by the plant operator and
following the manufacturer's operating constructions.
After every change of attachment, the operator has to
ensure the correct fastening and / or lock of the quick
exchange device.
Work on braking, steering, hydraulic and electric systems
of the earth-moving machine may only be carried out by
expert personnel specially trained in these areas.
Stability must be ensured at all times during work on
earth-moving machines.
The working equipment must be secured against
movement by lowering them to the ground or equivalent
measures, e.g. stays, trestles. When the engine is
running, the unsecured articulation area of loaders with
articulated steering must not be entered.
When jacking up earth-moving machines, jacking devices
must be positioned sot that they cannot slip. Jacks must
be positioned and applied absolutely straight, without
tilting.
9 of 196

4950152-EN (09-08) VI Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
Assembly, maintenance, repair (Cont’d)
Raised earth-moving machines must be supported by
suitable structures such as crosswise stacks of planks,
square timbers or steel trusses.
Earth-moving machines which are raised with working
equipment must be stabilized by a supporting structure
immediately after lifting. Do not work under earth-moving
machines which are only supported by the hydraulics.
The engine/motor must be turned off prior to all
maintenance and repair work. These requirements may
only be ignored in the case of maintenance or repair work
which cannot be performed without the engine/motor
running.
Depressurize the hydraulic system when carrying out
maintenance and repair jobs. To do this, lower the working
equipment to the ground with the engine turned off and
operate all hydraulic system is depressurized.
Before working on the electrics or when performing arc
welding on the machine, the connection to the battery
must be interrupted.
When disconnecting the battery, first the negative pole
then the positive pole must be disconnected. The battery
must be reconnected in reverse order.
During repair work around the battery, the battery must be
covered with insulating material; tools should never be
placed on or near the battery.
Protective devices of moving machine parts may only be
opened or removed when the drive has been switched off
and cannot be switched on again by unauthorized
persons. Protective devices are e.g. engine/motor covers,
doors, protective grating, and trim.
Upon completion of assembly, maintenance or repair
work, all protective devices must once more be attached
in the proper manner.
Load-bearing parts of earth-moving machines may only
be welded following consultation with the manufacturer
and in accordance with recognized welding principles.
Overhead guards (FOPS) must not be welded or drilled in
any way which could impair their sturdiness.
Alterations, such as welding of the hydraulic system, may
only be undertaken with the manufacturer's permission.
Before commencing work on the hydraulic system, the
pilot pressure, back pressure and pressure inside the tank
must be let off.
Lubricants cannot be taken internally and repeated skin
contact should be avoided. There is no special danger to
health if lubricants are used correctly. Please follow the
safety recommendations issued by the mineral oil
companies.
Only the hoses specified by the manufacturer may be
used.
Hydraulic hoses must be routed and assembled by expert
personnel.
Never smoke or handle open flames near or around the
fuel tank and batteries.
Towing, loading, transportation
The towing of earth-moving machines may only be done
with towing devices sufficiently dimensioned.
The fixing devices specified by the manufacturer must be
employed.
For loading and transportation earth-moving machines
and all necessary auxiliary equipment must be secured
against unwanted movement.
The traveling gear and track-laying gear of earth-moving
machines must be sufficiently cleaned of mud, snow and
ice to ensure tat ramps can be driven up without risk of
slipping.
When the earth-moving machine is transported on lorries,
flatbed trailers or by rail, it has to be carefully secured with
wheel chocks and tie-downs at the fastening points.
Before setting off, the route to be taken must be examined
to determine whether the roads are wide enough,
entrances and passages under bridges are large enough
and that roads and bridges have sufficient carrying
capacity
10 of 196

4950152-EN (09-08) VII Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
Monitoring and inspections
The machine must be thoroughly inspected by an
authorized and trained person according to the safety
regulations valid in your country:
• Prior to the first commissioning and prior to re-
commissioning after major changes
• At least once a year
• Periodically according to the operating conditions and
the conditions in the operator's company
The inspection report is to be put in writing and kept for
future reference.
Furthermore, prior to each work shift, the machine
operator must check the earth-moving machine according
to the inspections chart.
Hydraulic hoses must be replaced as soon as the
following damages are recognized:
• Damages to the outer layer which reach the
intermediate layer
• Embrittled patches on the outer layer
• Deformations when under pressure or without
pressure which differ from the original shape of the
installed hose
• Leakages
• Damages to hose fittings or to the connection
between the fitting and the hose
The coolant level must only be checked when it has
cooled down; the cap must be turned carefully in order to
bleed off excess pressure.
Prior to operations, the machine operator must check the
function of the safety devices.
The machine operator must advise the supervisor
immediately - and the person relieving him, should there
be a change of operators - with regard to any
shortcomings.
In the event of shortcomings which jeopardize the
operating safety of the earth-moving machine, it must not
be used until these have been eliminated.
Fire protection
A fire extinguisher has to be stored in the operator's cab.
A fire extinguisher symbol has to be applied.
Emergency exit
The windscreen acts as an emergency exit. If a front
guard is fitted or this exit can no longer be used for any
other reason, an emergency hammer must be affixed at
an easily accessible place inside the driver's cab.
Other dangers
Failure of the hydraulics
If the hydraulic system fails due to a standstill of the diesel
engine, a defectiveness of the hydraulic oil leakage, only
the emergency functions „lower working equipment“
are possible.
MTK115002
11 of 196

4950152-EN (09-08) VIII Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
Pictogram
001 - 099 : General control
100 - 119 : Loader
120 - 139 : Excavator
140 - 149 : Backhoe excavator
150 - 159 : Universal-mounted excavator / loader
160 - 179 : Walking excavator
180 - 199 : Tunneling and mining machines / Rail-road excavator
200 - : Maintenance, safety, etc. in general
SYMBOL DESCRIPTION SYMBOL DESCRIPTION
001 Battery charge
indicator
012 Hydraulic oil,
hydraulic oil level
002 Pre-heat 013 Hydraulic oil
temperature
003 Engine oil pressure 014 Hydraulic oil filter
clogging indicator
004 Engine oil
temperature
015 Horn
005 Engine oil level 016 Operational status,
operating hours
006 Coolant temperature 017 Parking brake
007 Coolant level 018 Brake accumulator
pressure
008 Air filter 019 Excavator brake
009 Fuel, fuel level 020 Service brake
010 Fan, Heater /
ventilation
021 Hazard warning
system
011 Windscreen wash/
wipe system
022 Direction indicator,
left/right
12 of 196

4950152-EN (09-08) IX Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
Pictogram (Cont’d)
023 Working floodlights 039 Speed control
024 Upper beam indicator 040 Oscillating axle lock
025 Direction of travel
forward/reverse
041 Steering inversion
026 Rotating beacon 042 All-wheel steering
crab / round steer
027 Light, lower beam 043 Rocker pedal for
travel
028 Central grease
system
044 Only shift when
machine is at
standstill
029 Lashing points 045 High gear
030 Overload warning
device / Overload
warning indicator
046 Cabin lift / lower
031 Suspension point for
loading by crane
047 Steering control
display
032 Travel speed, fast 048 First aid kit
033 Travel speed, slow 049 Fire extinguisher
034 Working hydraulics
cut-off, excavator;
loader / crane
050 Switch-over monitor
for operating hours
and time
035 Unlocked 051 Swing limitation,
engine stop override
036 Locked 052 Switch for all-wheel
steering
037 Float position 053 Interior lighting
038 Dozer blade 054 Reset hydraulic pulley
block (crane)
13 of 196

4950152-EN (09-08) X Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
055 Quick movement
hoisting winch
071 Danger of crushing
056 Cable uncoil limit
switch
072 Danger of injury
057 Auxiliary winch 073 Observe notes in
operating instructions
058 Magnet system 074
059 Hydraulic rock
breaker
075 Linde - no load
automatics
060 Electric boom height
limitation
076 Remote control
061 Undercarriage-
adjustment
077 Warning - general
062 Switch-over swing
speed, engine speed
adjustment
078 Temperature - general
063 Free fall mode 079
064 Grab rotation 080
065 Bucket return
positioning, lifting
frame height limitation
100 Control by joystick
066 Ride control system 101
067 Bucket return
positioning
102 Quick mount-hitch
lock
068 Hydraulic oil level 103
070 Safety distance, see
item 202
104 Water pump for
sweeper
14 of 196

4950152-EN (09-08) XI Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
105 Warning lamp
gearbox
151 Universal-mounted
excavator/loader (AL)
controls
120 Control 152 ISO control system
right
121 ISO control system-
let control system-
right
excavator / loader
(AL) controls
122 Control 154 control system right
123 ISO control system
right
excavator / loader
(AL) controls
124 Control control
system left
160 control system right
125 Control 161 Universal-mounted
excavator / loader
(AL) controls
126 Intermediate boom
(articulated boom
type)
162 Outrigger right
127 Control 163 Universal-mounted
excavator / loader
(AL) controls
128 Telescopic stick in /
out
164 Outrigger left
140 Control 165 Control
150 Articulation
„Knickmatik
166 Outrigger leg left
15 of 196

4950152-EN (09-08) XII Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
167 Outriggers spread 200 Grease gun
168 Outriggers lift / lower 201 Danger
169 Steering mode switch
HS 41 MM
202 On the machine:
caution, safety
distance
170 Outrigger left 203 In the operating
manual: warning
171 Outrigger right 204 Note
180 Switch-over diesel
drive
205 Scoot filter
181 Switch-over electric
drive
182 Diesel engine ignition
lock
183 Pony Truck IN
184 Pony Truck OUT
185 Electric motor START
186 Electric motor
emergency OFF
187 Cable drum (cable
winch)
R
16 of 196

4950152-EN (09-08) 10-01 Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
SAFETY AND MAINTENANCE
GENERAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
INSPECTION PARTS AND AIDS. . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
CARE AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
NOTES FOR WINTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Battery charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
CHECKING, MAINTENANCE AND INSPECTION PLANS . . . . . . 10-120-1
Initial inspection (delivery / handing-over inspection). . . . . . . . . 10-110-1
Daily and weekly tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
OVERVIEW OF LUBRICATING POINTS. . . . . . . . . . . . . . . . . . . . 10-120-1
INSPECTION AND MAINTENANCE WORK . . . . . . . . . . . . . . . . . 10-120-1
Inspection plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-5
Engine oil cooler (AL275). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-7
Engine Oil (Cont’d)10-110-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-8
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-10
Air filter, air intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-15
Inspection and maintenance work (Cont’d) . . . . . . . . . . . . . . . 10-110-18
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-20
Hydraulic oil cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-20
Hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-21
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-24
Injection valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-24
Toothed belt for engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-24
Electrical equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-25
Cab ventilation dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-26
Wind shield washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-26
SAFETY AND
MAINTENANCE
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4950152-EN (09-08) 10-02 Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
SHUTDOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Preservation (temporary shutdown) . . . . . . . . . . . . . . . . . . . . . . 10-110-1
During shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
After shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
REGULAR OIL ANALYSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Advantages of an oil analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil analysis intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
18 of 196

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4950152-EN (09-08) 10-10-1 Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
GENERAL NOTES
The good operating condition and life expectancy of
machines is largely influenced by care and maintenance.
For this reason, it is in every machine owner’s interest to
perform the specified maintenance work and comply with
the service intervals. In detail, this Chapter deals with
periodic maintenance, inspection and lubricating tasks.
The type-specific maintenance and inspection plan lists
all work to be performed on the machine at regular
intervals. Maintenance and inspection plans for this
purpose are contained in every instruction book.
It is essential that the recommendations in "SAFETY
INSTRUCTIONS" on page II are observed.
19 of 196

4950152-EN (09-08) 10-20-1 Bobcat AL275 / AL350 / AL440
SERVICE MANUAL
INTERVALS
First inspection Once before first putting into operation See “Initial inspection (delivery /
handing-over inspection)” on
page 10-70-1.
Daily jobs Every 10 operating hours or every work shift
1)
See “Daily and weekly tasks” on
page 10-70-2
.
Weekly jobs Weekly or after 50 operating hours 1)
AL275 See “Inspection plan” on page 10-
90-1
Every 10 operating hours Every 10 operating hours or every work shift
1)
Every 100 operating hours Once after first putting into operation 2)
Every 200 operating hours After every 200 operating hours
Every 400 operating hours After every 400 operating hours or 12 months
1)
1)
Every 1,500 operating hours After every 1,500 operating hours or 12
months 1)
months 1)
AL350 / AL440
Every 10 operating hours Every 10 operating hours or every work shift
1)
1)
1)
1)
1)
months 1)
months 1)
1) Whichever comes first.
2) Also applicable when new or overhauled diesel engines are put into operation.
21 of 196

Bobcat al275 wheel loader service repair manual sn adbh11001 & above

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